BACKGROUND OF THE INVENTION
[0001] Transparent blends of polycarbonates and polyester have been known for several decades.
Property wise they represent an amalgamation of various properties of the two polymer
systems — some properties of one being boosted, but usually at the expense of the
other polymer's property. Some of the areas that could use overall improvement are
impact, particularly low temperature impact, solvent resistance, and high melt flow.
Through the addition of a copolycarbonate system, we have maintained light transmission
characteristics of the polycarbonate polyester system while significantly improving
its ductility particularly at low temperature, after aging, and in the presence of
steam, while having improved solvent resistance to basic organic chemical system.
[0002] One application where thermoplastic polycarbonate-polyesters blends are especially
useful is in cellular telephones and other personal electronic devices. Due to continuing
innovation in function and design, more robust materials are required, but such materials
must also meet stringent manufacturing process requirements. For example, current
design trends for cellular telephones and other personal electronic devices phones
require use of in-mold-decoration (IMD) processes, in-mold-labeling (IML) processes,
over-molding (or two-shot molding) processes, and thin-wall molding. Part thickness
for these devices has evolved from about 1.5 to 2.0 mm down to 0.8 to 1.2 mm, and
even as thin as 0.5 mm. In addition, complicated design structures are required, including
lens covers (windows) with curvatures, lens covers with camera holes, integrated lens
covers and housings, and the like. Lens covers must be able to provide protection
to the devices inside the phone and/or allow see-through.
[0003] In IMD (also called "ink transfer" processes), since the carrier for the pattern
and the ink pattern itself cannot withstand very high temperatures, materials moldable
at lower injection molding temperatures are preferred, to prevent ink washout. The
thermoplastic materials also advantageously have high flow, to minimize mold-in stress
that can damage the carrier and the printed layer. Lower processing temperatures are
also preferred for in-mold labeling (IML) and two-shot molding processes. In two-shot
molding processes, it is critical that the thermoplastic material of the second shot
has a lower melt temperature than the thermoplastic material of the first shot, to
protect the first shot from washout or warpage caused by the hot melt of the second
shot. Thin parts not only require high flow but also high impact from the material
used. Industrial designers are increasing integrating several of the above design
trends into one application, for example a cellular phone cover housing with a camera
hole area, a transparent lens area and some geometric features, which is produced
by a two-shot molding process, where the first shot is a high-temperature opaque-colored
polycarbonate, and the second shot is a low temperature high flow transparent material,
which is covered with IMD print and has a wall thickness of about 0.5 mm.
[0004] Acrylic resins such as poly(methyl methacrylate) (PMMA) have been used in the foregoing
processes, because such resins are transparent and have a process temperature of about
220 to 230°C. However, the brittleness of PMMA and other acrylic-based resins limit
their use as cellular phone lenses with curvature designs and complicated structural
features. Polycarbonate alone provides high impact strength, but is processed at higher
temperatures, usually about 290 to 310°C. Higher flow polycarbonates are available,
but show insufficient impact strength for these applications due to the fact that
the higher flow is achieved at least in part by using a lower molecular weight polycarbonate.
Efforts to increase the flow of polycarbonate-polyester compositions, for example
by reducing the molecular weight of the polycarbonate resin, often results in the
loss of ductility.
[0005] Document
EP0537577 A1 discloses transparent compositions comprising 20 wt.% polysiloxane-polycarbonate
block copolymer (fully aromatic), 60 wt.% cycloaliphatic polyester (81 mole% cyclohexanedimethanol)
and 20 wt.% bisphenol-A based polycarbonate. It is silent about the melt flow rate.
[0006] There accordingly remains a need the art for polycarbonate-polyester blends that
have high flow at lower temperatures, that can be manufactured to be transparent,
and that can maintain good impact properties.
SUMMARY OF THE INVENTION
[0007] In accordance with the invention, there is a composition comprising, based on the
total weight of polymer components in the composition, about 3 to about 15 wt % of
a polysiloxane polycarbonate block copolymer comprising repeating structural units
of formula (I)
wherein at least 60 percent of the total number of R
1 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals, and repeating structural units of formula (IV)
wherein R
2 is independently at each occurrence a monovalent organic radical having I to 13 carbon
atoms, R
3 is a divalent aliphatic radical having 1 to 8 carbon atoms or an aromatic radical
having 6 to 8 carbon atoms, R
4 is independently at each occurence a hydrogen, halogen, alkaxy having 1 to 8 carbon
atoms, alkyl having 1 to 8 carbon atoms, or aryl having 6 to 13 carbon atoms, and
n is an integer less than or equal to 1000 ; about 33 to about 77 wt % of a cycloaliphatic
polyester having repeating units of formula (VI)
wherein R
7 and R
8 are independently at each occurrence a divalent aromatic, aliphatic or cycloaliphatic
group having 2 to 20 carbon atoms, with the proviso that at least one of R
7 and R
8 is a cycloaliphatic group-containing radical; and about 17 to about 65 wt % of a
polycarbonate that is different from the polycarbonate block copolymer, having a weight
average molecular weight of less than about 20,000 Daltons, and that comprises repeating
structural units of formula (XVIII)
wherein at least 60 percent of the total number of R
9 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals; and further herein the composition has a melt volume rate of
about 20 to about 40 cm
3/10 minutes, measured in accordance with ISO 1133 at 265°C and 2.16 kg.
[0008] In another embodiment, a composition comprises, based on the total weight of polymer
components in the composition, about 3 to about 15 wt % of a polysiloxane polycarbonate
block copolymer comprising repeating structural units of formula (I) wherein at least
60 percent of the total number of R
1 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals, and repeating structural units of formula (IV) wherein R
2 is independently at each occurrence a monovalent organic radical having 1 to 13 carbon
atoms, (see page 3) and n is an integer less than or equal to 1000, about 33 to about
77 wt °/u of a cycloaliphatic polyester having repeating units of formula (VI) wherein
R
7 and R
8 are independently at each occurrence a cycloaliphatic group-containing radical having
from 5 to 20 carbon atoms; and about 17 to about 65 wt % of a polycarbonate that is
different from the polycarbonate block copolymer, having a weight average molecular
weight of less than about 20,000 Daltons, and that comprises repeating structural
units of formula (XVIII) wherein at least 60% of the R
9 groups are derived from a bisphenol of formula (XX)
wherein R
10 and R
11 independently at each occurrence are a halogen atom or a monovalent hydrocarbon group,
p and q are each independently integers from 0 to 4, and X represents one of the groups
of formula (XXI) or (XXII)
wherein R
12 and R
13 independently at each occurrence are a hydrogen atom or a monovalent linear or cyclic
hydrocarbon group having 1 to 8 carbon atoms, and R
14 is a divalent hydrocarbon group having 1 to 8 carbon atoms; and further wherein the
composition has a melt volume rate of about 24 to about 35 cm
3/10 minutes, measured in accordance with ISO 1133 at 265°C and 2.16 kg.
[0009] In still another embodiment, a composition comprises, based on the total weight of
polymer components in the composition, about 4 to about 7 wt % of a polysiloxane polycarbonate
block copolymer comprising repeating structural units of formula (I) wherein at least
60 wt % of the R
1 groups are derived from bisphenol A; repeating structural units of formula (IV)
wherein R
2 is independently at each occurrence a methyl, trifluoropropyl, or phenyl, R
3 is propylene, and n is an integer of about 10 to about 100; about 38 to about 70
wt % of poly(1,4-cyclohexane-dimethanol-1,4-dicarboxylate); and about 25 to about
55 wt of a polycarbonate that is different from the polycarbonate block copolymer,
having a weight average molecular weight of less than about 19,000 Daltons, and that
comprises repeating structural units of formula (XVIII) wherein at least 60 percent
of the total number of R
9 groups are derived from bisphenol A; and further wherein the composition has a melt
volume rate of about 24 to about 35 cm
3/10 minutes, measured in accordance with ISO 1133 at 265°C and 2.16 kg.
[0010] Also disclosed is a method of manufacture of any of the above-described compositions,
comprising melt blending the components of the compositions.
[0011] Further disclosed is a method of forming an article comprising injection molding,
extrusion, injection blow molding, gas assist blow molding, or vacuum forming the
above-described compositions to form the article.
[0012] In another embodiment, an article comprises one of the above-described compositions.
BRIEF DESCRIPTION OF THE FIGURES
[0013] Figure 1 is six graphs (A-F) illustrating the effect of heat aging on weight average
molecular weight of various samples described below.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The inventors have found that a useful balance of properties can be obtained using
a blend of a specific type of a polyester, in particular a cycloaliphatic polyester,
and a specific type of polycarbonate copolymer, in particular a polycarbonate copolymer
containing both aromatic polycarbonate units and polysiloxane units. Such blends have
excellent transparency, together with excellent hydrolytic stability, that is, stability
over time in the presence of heat and/or humidity. Other properties of the blends
can also be maintained, in particular solvent resistance and impact properties, particularly
at low temperature.
[0015] In another embodiment, it has unexpectedly been found that the properties of the
blends, in particular flow at lower processing temperatures, can be improved even
further. Such improvements are obtained by use of a polyorganosiloxane/polycarbonate
block copolymer having a specific molecular weight range, in particular less than
20,000 Daltons, especially less than 19,000 Daltons. The improvements are obtained
without significantly adversely affecting other desirable properties of the polycarbonates,
in particular light transmittance and impact properties, particularly at low temperature.
These blends are especially useful in the formation of thin, transparent parts, for
example transparent cell phone covers.
[0016] The singular forms "a", "an", and "the" include plural referents unless the context
clearly dictates otherwise. "Optional" or "optionally" as used herein means that the
subsequently described event or circumstance may or may not occur, and that the description
includes instances where the event occurs and instances where it does not.
[0017] The polyorganosiloxane/polycarbonate block copolymer comprises polycarbonate blocks
and polyorganosiloxane blocks. The polycarbonate blocks comprise repeating structural
units of the formula (I),
in which at least 60 percent of the total number of R
1 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals. R
1 may be an aromatic organic radical of the formula (II),
wherein each of A
1 and A
2 is a monocyclic divalent aryl radical and Y
1 is a bridging radical having one or two atoms which separate A
1 from A
2. In one embodiment, one atom separates A
1 from A
2. Illustrative non-limiting examples of radicals of this type include -O-, -S-, -S(O)-,
-S(O)
2-, -C(O)-, methylene, cyclohexyl-methylene, 2-[2.2.1]-bicycloheptylidene, ethylidene,
isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene,
and adamantylidene. The bridging radical Y
1 may be an unsaturated hydrocarbon group or a saturated hydrocarbon group such as
methylene, cyclohexylidene, or isopropylidene.
[0018] The polyorganosiloxane blocks comprise repeating structural units of the formula
(IV),
wherein R
2 is independently at each occurrence a monovalent organic radical having 1 to 13 carbon
atoms. R
3 is independently at each occurrence a divalent aliphatic radical having 1 to 8 carbon
atoms or aromatic radical having 6 to 8 carbon atoms. In one embodiment each occurrence
of R
3 is in the ortho or para position relative to the oxygen. R
4 is independently at each occurrence a hydrogen, halogen, alkoxy having 1 to 8 carbon
atoms, alkyl having 1 to 8 carbon atoms or aryl having 6 to 13 carbon atoms and "n"
is an integer less than or equal to about 1000, specifically less than or equal to
about 100, or, more specifically, less than or equal to about 75 or, even more specifically,
less than or equal to about 60. As is readily understood by one of ordinary skill
in the art, n represents an average value.
[0019] In one embodiment in the above formula (IV), R
2 is independently at each occurrence an alkyl radical having 1 to 8 carbons, R
3 is independently at each occurrence a dimethylene, trimethylene or tetramethylene,
R
4 is independently at each occurrence a halogen radical, such as bromo and chloro;
alkyl radical such as methyl, ethyl, and propyl; alkoxy radical such as methoxy, ethoxy,
and propoxy; aryl radical such as phenyl, chlorophenyl, and tolyl. In one embodiment
R
3 is methyl, a mixture of methyl and trifluoropropyl, or a mixture of methyl and phenyl.
[0020] The polyorganosiloxane/polycarbonate copolymers may have a -average molecular weight
(, measured, for example, by ultra-centrifugation or light scattering, of greater
than or equal to about 10,000 to about 200,000, or, more specifically, about 20,000
to about 100,000. It is generally desirable to have polydimethylsiloxane units contribute
about 0.5 to about 80 weight percent of the total weight of the polyorganosiloxane/polycarbonate
copolymer or an equal molar amount of other polydiorganosiloxane. Even more specific
is a range of about 1 to about 10 weight percent of siloxane units in the polyorganosiloxane/polycarbonate
copolymer.
[0021] The polyorganosiloxane/polycarbonate block copolymer comprises polyorganosiloxane
domains having an average domain size of less than or equal to 45 nanometers- Within
this range the polyorganosiloxane domains may be greater than or equal to about 5
nanometers. Also within this range the polyorganosiloxane domains may be less than
or equal to about 40 nanometers, or, more specifically, less than or equal to about
10 nanometers.
[0022] Domain size may be determined by Transmission Electron Microscopy (TEM) as follows.
A sample of the polyorganosiloxane/polycarbonate block copolymer is injection molded
into a sample 60 millimeters square and having a thickness of 3.2 millimeters. A block
(5 millimeters by 10 millimeters) is cut from the middle of the sample. The block
is then sectioned from top to bottom by an ultra microtome using a diamond knife at
room temperature. The sections are 100 nanometers thick. At least 5 sections are scanned
by TEM at 100 to 120 kilovolts (kV) and the images recorded at 66,000X magnification.
The polysiloxane domains were counted and measured, the domain size reflecting the
longest single linear dimension of each domain. The domain sizes over the 5 sections
were then averaged to yield the average domain size.
[0023] Also specifically envisioned are polyorganosiloxane/polycarbonate block copolymers
prepared by direct synthesis comprising a polycarbonate matrix and the desired embedded
polysiloxane domains. In a blend of two polyorganosiloxane/polycarbonate copolymers
the individual copolymers are generally difficult to separate or to distinguish. With
Transmission Electron Microscopy (TEM) it is however possible to distinguish in the
blend a polycarbonate matrix and embedded polysiloxane domains.
[0024] Polyorganosiloxane/polycarbonate copolymers may be made by a variety of methods such
as interfacial polymerization, melt polymerization, and solid-state polymerization.
For example, the polyorganosiloxane/polycarbonate copolymers may be made by introducing
phosgene under interfacial reaction conditions into a mixture of a dihydric aromatic
compound, such as bisphenol A (hereinafter at times referred to as BPA), and a hydroxyaryl-terminated
polyorganosiloxane. The polymerization of the reactants may be facilitated by use
of a tertiary amine catalyst or a phase transfer catalyst.
[0025] The hydroxyaryl-terminated polyorganosiloxane may be made by effecting a platinum
catalyzed addition between a siloxane hydride of the formula (V),
and an aliphatically unsaturated monohydric phenol wherein R
2 and n are as previously defined.
[0026] Non-limiting examples of the aliphatically unsaturated monohydric phenols, which
may be used to make the hydroxyaryl-terminated polyorganosiloxanes include, for example,
4-allyl-2-methoxy phenol (herein after referred to as eugenol); 2-alkylphenol, 4-allyl-2-methylphenol;
4-allyl-2-phenylphenol; 4-allyl-2-bromophenol; 4-allyl-2-t-butoxyphenol; 4-phenyl-2-phenylphenol;
2-methyl-4-propylphenol; 2-allyl-4,6-dimethylphenol; 2-allyl-4-bromo-6-methylphenol;
2-allyl-6-methoxy-4-methylphenol and 2-allyl-4,6-dimethylphenol. Mixtures of aliphatically
unsaturated monohydric phenols may also be used.
[0027] Among the suitable phase transfer catalysts which may be utilized are catalysts of
the formula (R
5)
4Q
+X, where R
5 is independently at each occurrence an alkyl group having 1 to 10 carbons, Q is a
nitrogen or phosphorus atom, and X is a halogen atom, or an —OR
6 group, where R
6 is selected from a hydrogen, an alkyl group having I to 8 carbon atoms and an aryl
group having 6 to 18 carbon atoms. Some of the phase transfer catalysts which may
be used include [CH
3(CH
2)
3]
4NX, [CH
3(CH
2)
3]
4PX, [CH
3(CH
2)
5]
4NX, [CH
3(CH
2)
6]
4NX, [CH
3(CH
2)
4]
4NX, CH
3[CH
3(CH
2)
3]
3NX, CH
3[CH
3(CH
2)
2]
3NX wherein X is selected from Cl
-, Br
- or —OR
6. Mixtures of phase transfer catalysts may also be used. An effective amount of a
phase transfer catalyst is greater than or equal to 0.1 weight percent (wt %) and
in one embodiment greater than or equal to 0.5 wt % based on the weight of bisphenol
in the phosgenation mixture. The amount of phase transfer catalyst may be less than
or equal to about 10 wt % and more specifically less than or equal to 2 wt % based
on the weight of bisphenol in the phosgenation mixture.
[0028] Non-limiting examples of dihydric aromatic compounds which may be subjected to phosgenation
include, resorcinol; 4-bromoresorcinol; hydroquinone; 4,4'-dihydroxybiphenyl; 1,6-dihydroxynaphthalene;
2,6-dihydroxynaphthalene; bis(4-hydroxyphenyl)methane; bis(4-hydroxyphenyl)diphenylmethane;
bis(4-hydroxyphenyl)-1-naphthylmethane; 1,1-bis(4-hydroxyphenyl)methane; 1,1-bis(4-hydroxyphenyl)ethane;
1,2-bis(4-hydroxyphenyl)ethane; 1,1 -bis(4-hydroxyphenyl)-1-phenylethane; 2,2-bis(4-hydroxyphenyl)propane;
2-(4-hydroxyphenyl)-2-)3-hydroxyphenyl)propane; 2,2-bis(4-hydroxyphenyl)butane; 2,2-bis(4-hydroxyphenyl)
octane; 1,1-bis(4-hydroxyphenyl)propane; 1,1-bis(4-hydroxyphenyl)n-butane; bis(4-hydroxyphenyl)phenylmethane;
2,2-bis(4-hydroxy-1-methylphenyl) propane; 1,1-bis(4-hydroxy-tert-butylphenyl)propane;
2,2-bis(4-hydroxy-3-bromophenyl)propane; 1,1-bis (hydroxyphenyl)cyclopentane; 1,1-bis(4-hydroxyphenyl)cyclohexane;
1,1-bis(4-hydroxyphenyl)isobutene; 1,1-bis(4-hydroxyphenyl)cyclododecane; trans-2,3-bis(4-hydroxyphenyl)-2-butene;
2,2-bis(4-hydroxyphenyl)adamantine; (alpha, alpha'-bis(4-hydroxyphenyl)toluene. bis(4-hydroxyphenyl)acetonitrile;
2,2-bis(3-methyl-4-hydroxyphenyl)propane; 2,2-bis(3-ethyl-4-hydroxyphenyl)propane;
2,2-bis(3-n-propyl-4-hydroxyphenyl)propane; 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane;
2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane; 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane;
2,2-bis(3-cyclohexyl-4-hydroxyphenyl)propane; 2,2-bis(3-allyl-4-hydroxyphenyl)propane;
2,2-bis(3-methoxy-4-hydroxyphenyl)propane; 2,2-bis(4-hydroxyphenyl)hexafluoropropane;
1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene; 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene;
1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene; 4,4'-dihydroxybenzophenone;
3,3-bis(4-hydroxyphenyl)-2-butanone; 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione; ethylene
glycol bis(4-hydroxyphenyl)ether; bis(4-hydroxyphenyl)ether; bis(4-hydroxyphenyl)sulfide;
bis(4-hydroxyphenyl)sulfoxide; bis(4-hydroxyphenyl)sulfone; 9,9-bis(4-hydroxyphenyl)fluorine;
2,7-dihydroxypyrene; 6,6'-dihydroxy-3,3,3',3'- tetramethylspiro(bis)indane("spirobiindane
bisphenol"); 3,3-bis(4-hydroxyphenyl)phthalide; 2,6-dihydroxydibenzo-p-dioxin; 2,6-dihydroxythianthrene;
2,7-dihydroxyphenoxathin; 2,7-dihydroxy-9,10-dimethylphenazine; 3,6-dihydroxydibenzofuran;
3,6-dihydroxydibenzothiophene and 2,7-dihydroxycarbazole. Mixtures of dihydric aromatic
compounds may also be used.
[0029] The polyorganosiloxane/polycarbonate block copolymer may be produced by blending
aromatic dihydroxy compound with an organic solvent and an effective amount of phase
transfer catalyst or an aliphatic tertiary amine, such as triethylamine, under interfacial
conditions. Sufficient alkali metal hydroxide may be utilized to raise the pH of the
bisphenol reaction mixture prior to phosgenation, to 10.5 pH. This may result in the
dissolution of some of the bisphenol into the aqueous phase. Suitable organic solvents
that may be used are, for example, chlorinated aliphatic hydrocarbons, such as methylene
chloride, chloroform, carbon tetrachloride, dichloroethane, trichloroethane, tetrachloroethane,
dichloropropane, and 1,2-dichloroethylene; substituted aromatic hydrocarbons such
as chlorobenzene, o-dichlorobenzene, and the various chlorotoluenes. Mixtures of organic
solvents may also be used. In one embodiment the solvent comprises methylene chloride.
[0030] Aqueous alkali metal hydroxide or alkaline earth metal hydroxide addition may be
used to maintain the pH of the phosgenation mixture near the pH set point, which may
be in the range of 10 to 12. Some of the alkali metal or alkaline earth metal hydroxides,
which may be employed, are for example, sodium hydroxide, potassium hydroxide, and
calcium hydroxide. In one embodiment the alkali metal hydroxide used comprises sodium
hydroxide.
[0031] During the course of phosgene introduction at a pH of 10 to 12, and depending upon
the rate of phosgene addition, the pH may be lowered to allow for the introduction
of the hydroxyaryl-terminated polyorganosiloxane. End-capping agents such as phenol,
p-butylphenol, p-cumylphenol, octylphenol, nonylphenol, and other mono hydroxy aromatic
compounds may be used to regulate the molecular weight or to terminate the reaction.
[0032] Alternatively the polyorganosiloxane/polycarbonate copolymer may be produced by an
aromatic dihydroxy compound in the presence of a phase transfer catalyst at a pH of
5 to 8 to form bischloroformate oligomers. Then to this is added a hydroxyaryl-terminated
polyorganosiloxane, which is allowed to react at a pH of 9 to 12 for a period of time
sufficient to effect the reaction between the bischloroformate oligomers and the hydroxyaryl-terminated
polydiorganosiloxane, typically a time period of 10 to 45 minutes. Generally there
is a large molar excess of chloroformate groups relative to hydroxyaryl groups. The
remaining aromatic dihydroxy compound is then added, and the disappearance of chloroformates
is monitored, usually by phosgene paper. When substantially all chloroformates have
reacted, an end-capping agent and optionally a trialkylamine are added and the reaction
phosgenated to completion at a pH of 9 to 12.
[0033] The polyorganosiloxane/polycarbonate copolymer may be made in a wide variety of batch,
semi-batch or continuous reactors. Such reactors are, for example, stirred tank, agitated
column, tube, and recirculating loop reactors. Recovery of the polyorganosiloxane/
polycarbonate copolymer may be achieved by any means known in the art such as through
the use of an anti-solvent, steam precipitation or a combination of anti-solvent and
steam precipitation.
[0034] The thermoplastic composition may comprise blends of two or more polyorganosiloxane/polycarbonate
block copolymers. These block copolymers are transparent or translucent.
[0035] The cycloaliphatic polyester in the thermoplastic composition comprises a polyester
having repeating units of the formula VI,
wherein R
7 and R
8 are independently at each occurrence an aryl, aliphatic or cycloalkane having 2 to
20 carbon atoms and chemical equivalents thereof, with the proviso that at least one
of R
7 and R
8 is a cycloalkyl containing radical. The cycloaliphatic polyester is a condensation
product where R
7 is the residue of a diol or chemical equivalents and R
8 is decarboxylated residue of a diacid or chemical equivalents. In one embodiment
cycloaliphatic polyesters are those wherein both R
7 and R
8 are cycloaliphatic-containing radicals.
[0036] Cycloaliphatic polyesters may be formed from mixtures of aliphatic diacids and aliphatic
diols but must contain at least 50 mole % of cyclic diacid and/or cyclic diol components,
the remainder, if any, being linear aliphatic diacids and/or diols.
[0037] The cycloaliphatic polyesters may be obtained through the condensation or ester interchange
polymerization of the diol or diol chemical equivalent component with the diacid or
diacid chemical equivalent component.
[0039] In one embodiment the cycloaliphatic radical R
8 is derived from the 1,4-cyclohexyl diacids with generally greater than about 70 mole
% thereof in the form of the trans isomer and the cycloaliphatic radical R
7 is derived from the 1,4-cyclohexyl primary diols such as 1,4-cyclohexyl dimethanol
with greater than about 70 mole % thereof in the form of the trans isomer. The cycloaliphatic
polyesters have a weight-average molecular weight (Mw), measured, for example, by
ultra-centrifugation or light scattering, of about 25,000 Daltons to about 85,000
Daltons. The weight average molecular weight is more specifically about 30,000 Daltons
to about 80,000 Daltons and most specifically about 60,000 to about 80,000 Daltons.
[0040] Other diols that may be used in the preparation of the cycloaliphatic polyester are
straight chain, branched, or cycloaliphatic alkane diols and may contain 2 to 20 carbon
atoms. Examples of such diols include, but are not limited to, ethylene glycol; propylene
glycol, i.e., 1,2- and 1,3-propylene glycol; 2,2-dimethyl-1,3-propane diol; 2-ethyl-2-methyl-1,3-propane
diol; 1,3- and 1,5-pentane diol; dipropylene glycol; 2-methyl-1,5-pentane diol; 1,6-hexane
diol; dimethanol decalin, dimethanol bicyclo octane; 1,4-cyclohexane dimethanol and
particularly its cis- and trans-isomers; 2,2,4,4-tetramethyl-1,3-cyclobutanediol (TMCBD);
triethylene glycol; 1;10-decane diol; and mixtures of any of the foregoing. In one
embodiment the diol or chemical equivalent thereof used is 1,4-cyclohexane dimethanol
or its chemical equivalents.
[0041] Chemical equivalents of the diols include esters, such as dialkylesters, diaryl esters,
and the like.
[0042] In one embodiment the diacids are cycloaliphatic diacids. This is includes carboxylic
acids having two carboxyl groups each of which is attached to a saturated carbon.
Specific diacids are cyclo or bicyclo aliphatic acids, non-limiting examples of which
include, decahydro naphthalene dicarboxylic acids, norbornene dicarboxylic acids,
bicyclo octane dicarboxylic acids, 1,4-cyclohexanedicarboxylic acid, or chemical equivalents.
Most specifically the diacids include trans-1,4-cyclohexanedicarboxylic acid or chemical
equivalent. Linear dicarboxylic acids like adipic acid, azelaic acid, dicarboxyl dodecanoic
acid, and succinic acid may also be useful.
[0043] In a further embodiment the diacids are aromatic diacids, for example, terephthalic
acid and isophthalic acid. Cycloaliphatic or linear aliphatic diacids can be also
employed in a mixture with the aromatic diacids. Terephthalic and isophthalic acids
are preferred, most desirably being terephthalic acid. When there is no cycloaliphatic
diacid being employed, then at least some of the diols must be cycloaliphatic diol.
Various such diols have been disclosed and can be employed, the most desirable one
being 1,4-cyclohexanedimethanol, as previously disclosed. Various polymers can be
used with this dimethanol, particularly those with terephthalic acid such as those
with low levels of cyclohexanedimethanol and high levels of ethylene glycol such as
PETG, high levels of cyclohexanedimethanol and low levels of ethylene glycol such
as PCTG, and all cyclohexanedimethanol such as PCT. Other aliphatic diols can be used
such as butylene glycol or propylene glycol together with the cyclohexanedimethanol
and other cycloaliphatic diols as previously mentioned. PETG, PCTG, and PCT are the
most desirable.
[0044] Cyclohexane dicarboxylic acids and their chemical equivalents may be prepared, for
example, by the hydrogenation of cycloaromatic diacids and corresponding derivatives
such as isophthalic acid, terephthalic acid or naphthalenic acid in a suitable solvent
such as water or acetic acid using a suitable catalysts such as rhodium supported
on a carrier such as carbon or alumina. They may also be prepared by the use of an
inert liquid medium in which a phthalic acid is at least partially soluble under reaction
conditions and with a catalyst of palladium or ruthenium on carbon or silica.
[0045] Typically, in the hydrogenation, two isomers are obtained in which the carboxylic
acid groups are in cis- or trans-positions. The cis- and trans-isomers may be separated
by crystallization with or without a solvent, for example, using n-heptane, or by
distillation. The cis- and trans- isomers have different physical properties and may
be used independently or as a mixture. Mixtures of the cis- and trans-isomers are
useful herein as well.
[0046] When the mixture of isomers or more than one diacid or diol is used, a copolyester
or a mixture of two polyesters may be used as the cycloaliphatic polyester.
[0047] Chemical equivalents of these diacids may include esters, alkyl esters, e.g., dialkyl
esters, diaryl esters, anhydrides, salts, acid chlorides, acid bromides, and the like.
In one embodiment the chemical equivalent comprises the dialkyl esters of the cycloaliphatic
diacids, and most specifically the chemical equivalent comprises the dimethyl ester
of the acid, such as dimethyl-1,4-cyclohexane-dicarboxylate.
[0048] In one embodiment the cycloaliphatic polyester is poly(cyclohexane-1,4-dimethylene
cyclohexane-1,4-dicarboxylate) also referred to as poly(1,4-cyclohexane-dimethanol-1,4-dicarboxylate)
(hereinafter referred to as PCCD) which has recurring units of formula XVII,
[0049] With reference to formula VI for PCCD, R
7 is derived from 1,4-cyclohexane dimethanol; and R
8 is a cyclohexane ring derived from cyclohexanedicarboxylate or a chemical equivalent
thereof. The favored PCCD has a cis/trans formula.
[0050] The polyester polymerization reaction may be run in melt in the presence of a suitable
catalyst such as a tetrakis (2-ethyl hexyl) titanate, in a suitable amount, generally
50 to 200 ppm of titanium based upon the total weight of the polymerization mixture.
[0051] In one embodiment the cycloaliphatic polyester has a glass transition temperature
(Tg) greater than or equal to about 50°C, or, more specifically greater than or equal
to about 80°C, or, even more specifically, greater than or equal to about 100°C.
[0052] Also contemplated herein are the above polyesters with 1 to about 50 percent by weight
of units derived from polymeric aliphatic acids and/or polymeric aliphatic polyols
to form copolyesters. The aliphatic polyols include glycols, such as poly(ethylene
glycol) or poly(butylene glycol). Such polyesters may be made in accordance with the
processes disclosed in for example,
U.S. Pat. Nos. 2,465,319 and
3,047,539.
[0053] The thermoplastic composition optionally further comprises a polycarbonate resin.
Polycarbonate resins comprise repeating structural units of the formula XVIII,
in which at least 60 percent of the total number of R
9 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals. In one embodiment, R
9 is an aromatic organic radical and, more specifically, a radical of the formula (XIX),
—A
3—Y
2—A
4— (XIX);
wherein each of A
3 and A
4 is a monocyclic divalent aryl radical and Y
2 is a bridging radical having one or two atoms which separate A
3 from A
4. In an exemplary embodiment, one atom separates A
3 from A
4. Illustrative non-limiting examples of radicals of this type are -O-, -S-, -S(O)-,
-S(O)
2-, -C(O)-, methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylidene, ethylidene,
isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene,
and adamantylidene. The bridging radical Y
2 may be a hydrocarbon group or a saturated hydrocarbon group such as methylene, cyclohexylidene,
or isopropylidene.
[0054] Polycarbonates may be produced by the interfacial reaction of dihydroxy compounds
in which only one atom separates A
3 and A
4. As used herein, the term "dihydroxy compound" includes, for example, bisphenol compounds
having general formula XX as follow:
wherein R
10 and R
11 independently at each occurrence are a halogen atom or a monovalent hydrocarbon group;
p and q are each independently integers from 0 to 4; and X represents one of the groups
of formula XXI or XXII,
wherein R
12 and R
13 independently at each occurrence are a hydrogen atom or a monovalent linear or cyclic
hydrocarbon group having 1 to 8 carbons and R
14 is a divalent hydrocarbon group having 1 to 8 carbons.
[0055] Some illustrative, non-limiting examples of suitable dihydroxy compounds include
the dihydroxy-substituted aromatic hydrocarbons disclosed by name or formula (generic
or specific) in
U.S. Patent 4,217,438. A nonexclusive list of specific examples of the types of dihydroxy compounds includes
the following: resorcinol; 4-bromoresorcinol; hydroquinone; 4,4'-dihydroxybiphenyl;
1,6-dihydroxynaphthalene; 2,6-dihydroxynaphthalene; bis(4-hydroxyphenyl)methane; bis(4-hydroxyphenyl)diphenylmethane;
bis(4-hydroxyphenyl)-1-naphthylmethane; 1,1-bis(4-hydroxyphenyl)methane; 1,1-bis(4-hydroxyphenyl)ethane;
1,2-bis(4-hydroxyphenyl)ethane; 1,1 1-bis(4-hydroxyphenyl)-1-phenylethane; 2,2-bis(4-hydroxyphenyl)propane;
2-(4-hydroxyphenyl)-2-)3-hydroxyphenyl)propane; 2,2-bis(4-hydroxyphenyl)butane; 2,2-bis(4-hydroxyphenyl)
octane; 1,1-bis(4-hydroxyphenyl)propane; 1,1-bis(4-hydroxyphenyl)n-butane; bis(4-hydroxyphenyl)phenylmethane;
2,2-bis(4-hydroxy-1-methylphenyl) propane; 1,1-bis(4-hydroxy-tert-butylphenyl)propane;
2,2-bis(4-hydroxy-3-bromophenyl)propane; 1,1-bis (hydroxyphenyl)cyclopentane; 1,1-bis(4-hydroxyphenyl)cyclohexane;
1,1-bis(4-hydroxyphenyl)isobutene; 1,1-bis(4-hydroxyphenyl)cyclododecane; trans-2,3-bis(4-hydroxyphenyl)-2-butene;
2,2-bis(4-hydroxyphenyl)adamantine; (alpha, alpha'-bis(4-hydroxyphenyl)toluene bis(4-hydroxyphenyl)acetonitrile;
2,2-bis(3-methyl-4-hydroxyphenyl)propane; 2,2-bis(3-ethyl-4-hydroxyphenyl)propane;
2,2-bis(3-n-propyl-4-hydroxyphenyl)propane; 2,2-bis(3-isopropyl-4-hydroxyphenyl)propane;
2,2-bis(3-sec-butyl-4-hydroxyphenyl)propane; 2,2-bis(3-t-butyl-4-hydroxyphenyl)propane;
2,2-bis(3-cyclohexyl-4- hydroxyphenyl)propane; 2,2-bis(3-allyl-4-hydroxyphenyl)propane;
2,2-bis(3-methoxy-4-hydroxyphenyl)propane; 2,2-bis(4-hydroxyphenyl)hexafluoropropane;
1,1-dichloro-2,2-bis(4-hydroxyphenyl)ethylene; 1,1-dibromo-2,2-bis(4-hydroxyphenyl)ethylene;
1,1-dichloro-2,2-bis(5-phenoxy-4-hydroxyphenyl)ethylene; 4,4'-dihydroxybenzophenone;
3,3-bis(4-hydroxyphenyl)-2-butanone; 1,6-bis(4-hydroxyphenyl)-1,6-hexanedione; ethylene
glycol bis(4-hydroxyphenyl)ether; bis(4-hydroxyphenyl)ether; bis(4-hydroxyphenyl)sulfide;
bis(4-hydroxyphenyl)sulfoxide; bis(4-hydroxyphenyl)sulfone; 9,9-bis(4-hydroxyphenyl)fluorine;
2,7-dihydroxypyrene; 6,6'-dihydroxy-3,3,3',3'- tetramethylspiro(bis)indane("spirobiindane
bisphenol"); 3,3-bis(4-hydroxyphenyl)phthalide; 2,6-dihydroxydibenzo-p-dioxin; 2,6-dihydroxythianthrene;
2,7-dihydroxyphenoxathin; 2,7-dihydroxy-9,1 0-dimethylphenazine; 3,6-dihydroxydibenzofuran;
3,6-dihydroxydibenzothiophene and 2,7-dihydroxycarbazole. Mixtures of dihydroxy- compounds
may also be used.
[0056] It is also possible to employ two or more different dihydroxy compounds or a copolymer
of a dihydric phenol with a glycol or with a hydroxy-terminated or acid-terminated
polyester or with a dibasic acid or hydroxy acid in the event a carbonate copolymer
rather than a homopolymer is desired for use. Polyarylates and polyester-carbonate
resins or their blends may also be employed. Branched polycarbonates as well as blends
of linear polycarbonate and a branched polycarbonate may be employed. The branched
polycarbonates may be prepared by adding a branching agent during polymerization.
[0057] These branching agents are well known and may comprise polyfunctional organic compounds
containing at least three functional groups, which may be hydroxyl, carboxyl, carboxylic
anhydride, haloformyl, and mixtures thereof. Specific examples include trimellitic
acid, trimellitic anhydride, trimellitic trichloride, tris-p-hydroxy phenyl ethane,
isatin-bis-phenol, tris-phenol TC (1,3,5-tris((p-hydroxyphenyl)isopropyl)benzene),
tris-phenol PA (4(4(1,1 -bis(p-hydroxyphenyl)-ethyl) alpha, alpha-dimethyl benzyl)phenol),
4-chloroformyl phthalic anhydride, trimesic acid, and benzophenone tetracarboxylic
acid. The branching agents may be added at a level of 0.05-2.0 weight percent. Branching
agents and procedures for making branched polycarbonates are described in
U.S. Patent Nos. 3,635,895 and
4,001,184. Many types of polycarbonates end groups may be used in the polycarbonate composition.
[0058] In one embodiment polycarbonates are based on bisphenol A compound with formula XIX,
in which each of A
3 and A
4 is p-phenylene and Y
2 is isopropylidene. The weight average molecular weight of the polycarbonate may be
about 5,000 to about 100,000 daltons, or, more specifically about 10,000 to about
65,000 daltons, or, even more specifically, about 15,000 to about 35,000 daltons.
[0059] The components of the composition can be present in the following amounts. Polysiloxane
polycarbonate copolymer can be present in an amount of about 3 to about 15 wt % of
the composition. Also within this range, the copolymer can be present in an amount
less than or equal to about 60 wt %. The cycloaliphatic polyester can be present in
the composition in an amount of about 33 to about 77 wt %. The polyester can be present
in amounts greater than about 15 wt % and can be present in amounts less than about
50 wt %. The polycarbonate need not be present in the composition but, if it is present,
should not exceed quantities of about 15 wt % of the composition. A quantity of greater
than or about $ wt % of the composition can be employed. The polycarbonate when present
is generally less than about 65 wtt %.
[0060] Parts made from the compositions of this invention are translucent or transparent.
Transparent is measured as >70% transmission using ASTM D1003. Translucency is an
appearance state between complete opacity and complete transparency.
[0061] The addition of the polysiloxane/polycarbonate block copolymer to the cycloaliphatic
polyester blend brings about the following benefits: increased long term impact performance,
better low temperature ductility, and certain specific chemical resistance.
[0062] In a specific embodiment, it has been found that use of a polycarbonate having a
weight average molecular weight (Mw) of less than about 19,000 Daltons (19 KiloDaltons,
or KDa) and the block copolymer provides blends that have high flow at lower temperatures,
without significantly adversely affecting the other desirable properties of the compositions,
such as impact, ductility, transparency, and/or hydrolytic stability. The polycarbonates
can also have an Mw of 15 to 19 KDa, specifically 17 to 18 KDa. The block copolymer
can also have an Mw of 18 to 24 KDa.
[0063] In one embodiment, use of a polycarbonate having an Mw of less than about 19 KDa
and the block copolymer provides a composition that imparts equivalent transparency
and impact resistance, an improvement in melt flow of about 60 to about 80%, as compared
to the same composition containing polycarbonates having higher molecular weights
instead of the polycarbonate having molecular weight less than 19 KDa, when measured
at 265°C, using a 2.16 Kg weight in accordance with ISO 1133.
[0064] Such compositions can also have equivalent impact properties such as Notched Izod
ductility, Notched Izod impact strength at room temperature and at low temperature,
as well as heat deflection temperatures, that are comparable to the same compositions
with polycarbonates having higher molecular weights. This result is surprising, because
replacement of high molecular weight polycarbonates with lower molecular weight polycarbonates
often adversely affects impact properties:
[0065] For example, when measured at 23°C in accordance with ASTM-D256, an article such
as a molded bar comprising the compositions and having a thickness of 3.2 mm has a
Notched Izod impact strength of about 800 to about 1600 J/m. In addition, or alternatively,
an article such as a molded bar comprising the compositions and having a thickness
of 3.2 mm can have a Notched Izod impact strength of about 100 to about 1000 J/m,
measured in accordance with ASTM D-256 at 0°C.
[0066] An article such as a molded sample comprising the compositions and having a thickness
of 3.2 mm can have a heat deflection temperature of about 60 to about 90°C.
[0067] Substitutions of the higher molecular weight polycarbonate with the lower molecular
weight polycarbonate and the block copolymer also do not substantially adversely impact
the light transmittance of the compositions. An article molded from the composition
and having a thickness of 2.5 mm has a haze of less than or equal to 5% and/or a transparency
of greater than or equal to 80%, each measured according to ASTM D1003-00.
[0068] In this embodiment, the compositions comprise about 3 to about 15 wt % of polysiloxane/polycarbonate
block copolymer, about 33 to about 77 wt % of cycloaliphatic polyester, and about
17 to about 65 wt % of the polycarbonate having an Mw of less than about 20 KDa. Alternatively,
the compositions comprise about 3 to about 15 wt % of the polysiloxane/polycarbonate
block copolymer, about 33 to about 77 wt % of the cycloaliphatic polyester, and about
17 to about 65 wt % of the polycarbonate having an Mw of less than about 19 KDa. In
still another embodiment, the compositions comprise about 4 to about 7 wt % of the
polysiloxane/polycarbonate block copolymer, about 38 to about 70 wt % of the cycloaliphatic
polyester, and about 25 to about 55 wt % of the polycarbonate having an Mw of less
than about 19 KDa.
[0069] To prepare the resin composition, the components may be mixed by any known methods.
Typically, there are two distinct mixing steps: a premixing step and a melt mixing
("melt blending") step. In the premixing step, the dry ingredients are mixed together.
The premixing step is typically performed using a tumbler mixer or ribbon blender.
However, if desired, the premix may be manufactured using a high shear mixer such
as a Henschel mixer or similar high intensity device. The premixing step is typically
followed by a melt mixing step in which the premix is melted and mixed again as a
melt. Alternatively, the premixing step may be omitted, and raw materials may be added
directly into the feed section of a melt mixing device, preferably via multiple feeding
systems. In the melt mixing step, the ingredients are typically melt kneaded in a
single screw or twin screw extruder, a Banbury mixer, a two roll mill, or similar
device. The examples are extruded using a twin screw type extruder, where the mean
residence time of the material is from about 20 s to about 30 s, and where the temperature
of the different extruder zones is from about 230°C to about 290°C. The compositions
may be shaped into a final article by various techniques known in the art such as
injection molding, extrusion, injection blow molding, gas assist blow molding, or
vacuum forming.
[0070] The above-described compositions are especially useful in the manufacture of articles
made using IMD, IML, two-shot processes, thin parts, or any combination comprising
at least one of the foregoing processes. The impact properties of the compositions
are similar to that of polycarbonate. The high flow at lower processing temperatures
(e.g., about 250 to about 270°C) better protects ink patterns, labels, or parts.
[0071] Use of the compositions with lower molecular weight polycarbonates are even more
useful in some applications, because they can have high flow at even lower processing
temperatures (e.g., as low as about 230°C), without a significant decrease in impact
properties. These compostions accordingly provide a good balance among transparency,
high flow, low processing temperature, and impact.
[0072] The compositions are thus useful in the manufacture of components of hand-held electronic
devices such as personal digital assistants and cellular telephones, in particular
lens and combinations of lenses and covers. Other structural features that can be
present include camera lens holes, curvatures, snap fixes, hollow-out areas, thin
ribs or rings and other geometric structures.
[0073] For the test samples below, the compositions are injection molded using a VanDorn
85 or a Fanuc S-2000i with melt temperature set at 250 to 310 C or 250-270°C, mold
temperature set at 60°C, and cycle time from 30 to 35 s unless otherwise noted.
[0074] The following tests were run on the examples.
[0075] From the granulate, the melt volume rate (MVR) was measured according to ISO 1133
( 300 C/1.2kg or 265°C/2.16 Kg, unless otherwise stated) in units of cm
3/10 min.
[0076] Optical properties (transmission) are measured according to ASTM D1003 with 3.2 mm
or 2.5 mm thick plaques.
[0077] Notched Izod impact strength (INI) is measured according to ASTM D256 with 3.2 mm
thick Izod bars at various temperatures.
[0078] Thermal aging performance: the Izod bars are heated at 90°C for 15 hours in any oven,
then tested with INI at 23°C according to ASTM D256. The retention of INI after annealing
is utilized to characterize the thermal aging performance of a material. Autoclave:
the Izod bars are placed in any autoclave or steam sterilizer (e.g., Napco sterilizer)
at 120°C for 3.3 and 6.7 hours, respectively, then tested with INI at 23°C according
to ASTM D256. The retention of 1NI after autoclaving is utilized to characterize the
autoclavability of a material.
[0079] Chemical Resistance: Chemical resistance against various solvents is studied. A composition
having 0.3% alkyl dimethyl benzyl ammonium chloride, 0.5-5% ethylene glycol, buffered
to pH 11.6 in water is tested. The test is carried out according to ISO 4599. The
following test conditions are used: Duration of the test: 48 hours; Test temperature:
23°C; Applied constant strain: 0.5%. The method of contact: immersion. After the test,
the tensile test procedure according to the ASTM D638 standard is performed to determine
the physical properties. The sample is considered compatible to the chemical (or resistant
to the chemical) if the retention of tensile elongation at break is equal or above
80%; considered marginal if the elongation retention is between 65 and 79%; and considered
incompatible if the elongation retention is below 64%.
[0080] In the following examples, "PC" refers to a polycarbonate derived from bisphenol
A. The polyorganosiloxane/polycarbonate copolymer is represented by "t-EXL" or "PC-siloxane
copolymer" and contains 6 wt % siloxane units derived from a diol of formula (IV)
wherein R
2 is methyl, R
3 is propylene, and R
4 is methoxy.
[0081] Below in Table 1 are reference examples 1-7 together with control examples without
the polycarbonate polysiloxane block copolymer. C1, C2, and C3 are comparative examples.
Table 1
|
C1 |
C2 |
C3 |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
Formulations |
|
PC, Mw = 36 KDa |
74.2 |
0 |
49.9 |
28.1 |
0 |
54.2 |
0 |
19.1 |
34.5 |
12.4 |
PC, Mw = 30 KDa |
0.0 |
35 |
0 |
0.0 |
14.7 |
0.0 |
21.6 |
0 |
0 |
0 |
PC, Mw = 22 KDa |
0.0 |
38.0 |
24 |
0.0 |
27.4 |
0.0 |
21.6 |
0 |
17.0 |
5.9 |
PCTG |
25.0 |
26.3 |
0.0 |
15.0 |
15.0 |
20.0 |
26.3 |
42 |
0.0 |
0.0 |
PCT |
0.0 |
0.0 |
25 |
0.0 |
0.0 |
0.0 |
0.0 |
0 |
28.5 |
42.0 |
t-EXL (6 wt % siloxane) |
0.0 |
0.0 |
0.0 |
56.1 |
42.1 |
25.0 |
30.0 |
38.1 |
19.0 |
38.6 |
Properties |
|
MVR ISO at 265°C, 2.16 kg (cm3/10 min) |
3.0 |
12 |
6.3 |
4.5 |
9.2 |
3.8 |
12 |
6.2 |
5.3 |
5.8 |
% Transmission at 3.2 mm thickness |
87 |
88 |
86 |
83 |
84 |
85 |
86 |
84 |
84 |
84 |
INI at 23°C (J/m) |
980 |
760 |
700 |
950 |
910 |
1000 |
1000 |
960 |
909 |
917 |
INI at 0°C (J/m) |
130 |
110 |
95 |
940 |
800 |
860 |
825 |
910 |
405 |
168 |
INI at -30°C (J/m) |
80 |
75 |
75 |
580 |
545 |
180 |
150 |
125 |
120 |
150 |
INI retention after 15h annealing at 90°C |
10% |
10% |
10% |
95% |
91% |
87% |
26% |
16% |
40% |
60% |
INI retention after autoclave at 120°C for 3.3h |
10% |
10% |
NM |
90% |
NM |
94% |
NM |
N/A |
NM |
N/A |
INI retention after autoclave at 120°C for 6.7h |
10% |
10% |
NM |
90% |
NM |
85% |
NM |
N/A |
NM |
N/A |
Chemical resistance vs Formula 409* |
NM |
0% |
0% |
NM |
NM |
NM |
NM |
NM |
100% |
98% |
*% Retention in Tensile Elongation at Break after 2 days with 0.5% strain
NM - Not measured
N/A - Not applicable because heat deflection temperature at 66 psi is less than 120°C. |
[0082] The invention compositions having t-EXL provide excellent initial INI, which remain
very high, particularly the compositions with PCTG, when INI is measured at substantially
reduced temperatures of 0°C and -30°C. Additionally, after heating at 90°C for 15
hours, the INI is substantially retained, particularly with PCTG. The INI retention
after autoclaving is also high in the tested invention compositions. With respect
to solvent resistance against a specific basic material, the PCT containing compositions
demonstrate very little deterioration, if any.
[0083] The Examples in Table 2 illustrate the effect of varying the molecular weight of
the polycarbonate in the polyester and copolycarbonate blend, and the importance of
including the polyorganosiloxane/polycarbonate copolymer. Comparative Example C4 corresponds
to Example 8 without the polysiloxane copolymer; Comparative Example C5 corresponds
to Example 9 without the copolymer. Comparative example C6 contains polycarbonates
having weight average molecular weights of 22 and 30 KDa. Example 10 corresponds to
C6 in that it has a same percentage of polyester as C6, but lower molecular weight
polycarbonate and 6% PC/siloxane block copolymer
Table 2.
Components |
|
8 |
9 |
10 |
C4 |
C5 |
C6 |
PC, Mw = 18 KDa |
|
43.7 |
28.3 |
53.5 |
49.7 |
34.3 |
0 |
PC, Mw = 22 KDa |
|
0 |
0 |
0 |
0 |
0 |
49.5 |
PC, Mw = 30 KDa |
|
0 |
0 |
0 |
0 |
0 |
10.0 |
PCCD 2000 poise |
|
49.7 |
65.0 |
39.8 |
49.7 |
65.0 |
39.8 |
PC-siloxane copolymer |
|
6.0 |
6.0 |
6.0 |
0 |
0 |
0 |
Properties |
Units |
|
|
|
|
|
|
MVR ISO at 265°C, 2.16 kg |
cm3/10 min |
28.3 |
31.5 |
28.8 |
28.9 |
28.9 |
17.4 |
MVR ISO at 220°C, 2.16 kg |
cm3/10 min |
5.7 |
2.9 |
5.5 |
4.8 |
4.3 |
3.1 |
MVR ISO at 220°C, 5.00 kg |
cm3/10 min |
13.7 |
13.5 |
13.5 |
13.4 |
13.4 |
7.5 |
MVR ISO at 240°C, 2.16 kg |
cm3/10 min |
12.6 |
13.4 |
12.6 |
12.9 |
13.3 |
7.1 |
% Transmission at 2.5 mm thickness |
% |
90.6 |
90.9 |
90.0 |
90.2 |
90.6 |
89.8 |
%Haze at 2.5 mm thickness |
% |
1.2 |
1.3 |
1.1 |
1.2 |
2.0 |
1.0 |
INI at 0°C, 5 lbf/ft ductility |
% |
40 |
80 |
0 |
0 |
0 |
0 |
INI at 0°C, 5 lbf/ft Impact Strength |
J/m |
462 |
982 |
130 |
101 |
117 |
107 |
INI at 23°C, 5 lbf/ft Ductility |
% |
80 |
100 |
100 |
100 |
100 |
100 |
INI at 23°C, 5 lbf/ft Impact Strength |
J/m |
915 |
1520 |
942 |
909 |
1380 |
905 |
HDT at 0.45 MPa, 3.2 mm |
°C |
91.7 |
NM |
NM |
NM |
NM |
NM |
HDT at 1.82 MPa, 3.2 mm |
°C |
81.5 |
70.4 |
88.4 |
81.2 |
72.4 |
90.6 |
[0084] As can be seen from the data in Table 2, Examples 8, 9 and 10 had improved flow relative
to Example C6: MVR at 265°C / 2.16 Kg / 240 s was improved by approximately 60% to
80%. At the same time, the impact properties were maintained or even improved. At
23°C, the Notch Izod Impact Strength (INI) of examples 8 ,9 and 10 were the same or
higher than Example C6. At 0°C, examples 8 and 9 had even higher INI strength and
maintained certain ductility (40% to 80%) while there is a total ductility loss in
C6, and a much lower INI strength. Furthermore, the transparency (transmission and
haze) of examples 8 , 9, and 10 are very close to that of C6. Use of lower molecular
weight polycarbonate in the blends accordingly provides increased flow.
[0085] A comparison of Examples 8 and 9 with C4 and C5, respectively, show that replacing
polycarbonate with polyorganosiloxane/polycarbonate copolymer improved the low temperature
impact property to an even greater extent, but also maintained the transparency of
articles molded from the compositions. Comparing Example 8 with C4 and 9 with C5,
the optical properties remained the same for the siloxane blends. Since transparency
is important in applications such as cellular phone lens, it is desirable in these
applications to maintain a lower percentage of polyorganosiloxane/polycarbonate copolymer
(about 2 to about 20 wt %) in order to preserve a balance between attaining transparency
and good impact properties.
[0086] The data in Table 2 further illustrate the importance of the polyorganosiloxane/polycarbonate
copolymer in achieving good impact properties. The only difference between Examples
8 and 9, and Comparative Examples 4 and 5, respectively, is that the polyorganosiloxane/polycarbonate
copolymer in Examples 8 and 9 with polycarbonate. It can be seen that all of four
of these examples have the same flow properties as reflected by MVR. However, the
low temperature impact (INI ductility at 0°C) of Comparative Examples C4 and C5 is
decreased in the absence of the copolymer compared to Examples 8 and 9. Furthermore,
the impact property of example 10, which can be seen as obtained by replacing 90%
higher molecular weight polycarbonate with low (<19K Da) molecular weight polycarbonate
in C6 while in the presence of the copolymer, was retained similar at 23°C and 0°C
as in C6, yet the melt flow property (MVR) was improved 65%, and the optical properties
(transmission% and haze%) and HDT were retained similar.
[0087] Comparison of the MVR shift, PC Mw shift, and PCCD Mw shift of the four blends in
Table 3 shows that the blends containing the copolymer (Examples 8 and 9) have better
hydrolytic stability than their counterparts without the copolymer (Comparative Examples
4 and 5). Due to experimental set-up difference, the weight average molecular weight
(Mw) data in Table 3 were reported by polystyrene (PS) standard instead of Daltons
(Da) as in the rest of the invention. The MVR was measured according to ISO 1133 (265°C/2.16
kg/240 seconds). All measurements were done on the granules with or without aging
at 80°C /80 RH (relative humidity) for one to four weeks.
[0088] MVR increase in granules after hydrolytic aging is a sign of less hydrolytic stability
or more chemical degradation of the polymers and therefore is undesirable. The degradation
is also shown as decreases of the molecular weight of PC and/or polyester (PCCD).
Examples 8 and 9 showed better hydrolytic stability than the comparative examples
without the PC/polysiloxane block copolymer, C4 and C5, respectively. For example,
after 4 weeks aging at 80°C /80 RH, C4 had nearly 400% of MVR increase while 8 had
less than 100% MVR increase, also C4 retained 63% and 75% of the original Mw of PC
and PCCD respectively while 8 retained 85% and 92% of the original Mw of PC and PCCD
respectively. The comparison in Table 3 is further illustrated in Figure 1, graphs
A-E.
Table 3.
|
MVR (cm3/10 min)* |
Weeks |
8 |
C4 |
|
9 |
C5 |
0 |
28.4 |
30.8 |
|
34.8 |
29.2 |
1 |
31.7 |
36.0 |
|
36.4 |
41.5 |
2 |
35.5 |
45.2 |
|
52.6 |
85.9 |
3 |
43.0 |
73.3 |
|
91.4 |
193.7 |
4 |
54.4 |
149.2 |
|
146.8 |
434.1 |
MVR increase after 4 weeks aging at 80°C/80% RH |
92% |
384% |
|
322% |
1387% |
|
PC Mw** |
Weeks |
8 |
C4 |
|
9 |
C5 |
1 |
35752 |
34211 |
|
34357 |
31813 |
2 |
34071 |
30183 |
|
31186 |
24968 |
3 |
31593 |
27120 |
|
24327 |
18615 |
4 |
30266 |
21614 |
|
21058 |
15596 |
PC Mw retention after 4 weeks aging at 80°C/80% RH |
85% |
63% |
|
61% |
49% |
|
PCCD Mw** |
Weeks |
8 |
C4 |
|
9 |
C5 |
1 |
90431 |
86000 |
|
84306 |
84224 |
2 |
83291 |
80851 |
|
81590 |
69795 |
3 |
83175 |
78152 |
|
72344 |
58149 |
4 |
83507 |
64477 |
|
63092 |
52996 |
PCCD Mw retention after 4 weeks aging at 80°C/80% RH |
92% |
75% |
|
75% |
63% |
* MVR value of >200 cm3/10 min tend to have large variances. All MVR values were averaged from at least two
test results.
**By Polystyrene standard according to GE method. |
[0089] All references are incorporated herein by reference. The endpoints of all ranges
directed to the same component or property are inclusive of the endpoint and independently
combinable. Compounds are described using standard nomenclature. For example, any
position not substituted by any indicated group is understood to have its valency
filled by a bond as indicated, or a hydrogen atom. A dash ("-") that is not between
two letters or symbols is used to indicate a point of attachment for a substituent.
For example, -CHO is attached through carbon of the carbonyl group.
1. A composition comprising, based on the total weight of polymer components in the composition,
3 to 15 wt.% of a polysiloxane polycarbonate block copolymer comprising repeating
structural units of formula (I)
wherein at least 60 percent of the total number of R1 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals, and
repeating structural units of formula (IV)
wherein R2 is independently at each occurrence a monovalent organic radical having 1 to 13 carbon
atoms, R3 is a divalent aliphatic radical having 1 to 8 carbon atoms or an aromatic radical
having 6 to 8 carbon atoms, R4 is independently at each occurrence a hydrogen, halogen, alkoxy having 1 to 8 carbon
atoms, alkyl having 1 to 8 carbon atoms, or aryl having 6 to 13 carbon atoms, and
n is an integer less than or equal to 1000;
33 to 77 wt.% of a cycloaliphatic polyester having repeating units of formula (VI)
wherein R7 and R8 are independently at each occurrence a divalent aromatic, aliphatic or cycloaliphatic
group having 2 to 20 carbon atoms, with the provision that at least one of R7and R8 is a cycloaliphatic group-containing radical; and
17 to 65 wt.% of a polycarbonate that is different from the polycarbonate block copolymer,
having a weight average molecular weight of less than 20,000 Daltons, and that comprises
repeating structural units of formula (XVIII)
wherein at least 60 percent of the total number of R9 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals; and further
wherein the composition has a melt volume rate of 20 to 40 cm3/10 minutes, measured in accordance with ISO 1133 at 265°C and 2.16 kg, and
wherein a molded sample having a thickness of 3.2 mm has a Notched Izod impact strength
of 800 to 1600 J/m, measured in accordance with ASTM D-256 at 23°C.
2. The composition of claim 1, comprising 4 to 7 wt.% of the block copolymer, 38 to 70
wt.% of the cycloaliphatic polyester, and 25 to 55 wt.% of the polycarbonate.
3. The composition of claim 1, wherein a molded sample having a thickness of 3.2 mm has
a Notched Izod impact strength of 100 to 1000 J/m, measured in accordance with ASTM
D-256 at 0°C.
4. The composition of claim 1, wherein the composition retains at least 10 % more molecular
weight after aging for 28 days at 80°C, 80% relative humidity, as compared to a composition
without the polysiloxane polycarbonate block copolymer, and preferably the polycarbonate
of the composition retains at least 15 % more of its molecular weight after aging
for 28 days at 80°C, 80% relative humidity, as compared to a composition without the
polysiloxane polycarbonate block copolymer, or preferably the polyester of the composition
retains at least 10 % more of its molecular weight after aging for 28 days at 80°C,
80% relative humidity, as compared to a composition without the polysiloxane polycarbonate
block copolymer.
5. The composition of claim 1, wherein an article molded from the composition and having
a thickness of 2.5 mm has a haze of less than or equal to 5%, measured according to
ASTM D1003-00, or has a transparency of greater or equal to 80%, measured according
to ASTM D 1003-00, or wherein a molded sample having a thickness of 3.2 mm has a deflection
temperature of 60 to 90°C.
6. The composition of claim 1, wherein at least 60 wt.% of the R1 groups are radicals of the formula (XIX)
-A3-Y2-A4- (XIX)
wherein each of A3 and A4 is a monocyclic divalent aryl radical and Y2 is -0-, -S-, -S(O)-, -S(O)2-, -C(O)-, methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylidene, ethylidene,
isopropylidene, neopentylidene, cyclohexylidene, cyclopentadecylidene, cyclododecylidene,
adamantylidene, or a combination comprising at least one of the foregoing groups,
and further wherein R2 is independently at each occurrence a monovalent organic radical having 1 to 4 carbon
atoms, R3 is a divalent aliphatic radical having 3 to 8 carbon atoms, and n is an integer of
10 to 100, preferably each of A3 and A4 is phenylene and Y2 is isopropylidene, and R2 is methyl, R3 is a divalent aliphatic radical having 3 to 8 carbon atoms, and n is an integer of
40 to 60.
8. The composition of claim 1, wherein R8 is derived from 1,4-cyclohexyl dicarboxylic acid with greater than 70 mole % thereof
in the form of the trans isomer and R7 is derived from 1,4-cyclohexyl dimethanol with greater than 70 mole % thereof in
the form of the trans isomer.
9. The composition of claim 1, wherein R
9 comprises at least 60 wt.% of units of the formula (XX)
wherein R
10 and R
11 independently at each occurrence are a halogen atom or a monovalent hydrocarbon group;
p and q are each independently integers from 0 to 4; and X represents one of the groups
of formula (XXI) or (XXII)
wherein R
12 and R
13 independently at each occurrence are a hydrogen atom or a monovalent linear or cyclic
hydrocarbon group having 1 to 8 carbon atoms and R
14 is a divalent hydrocarbon group having 1 to 8 carbon atoms, preferably X is isopropylidene
and p and q is each zero.
10. A method of manufacture of the composition of claim 1, comprising melt blending the
components of the composition of claim 1.
11. A method for forming an article, comprising injection molding, extrusion, injection
blow molding, gas assist blow molding, or vacuum forming of the composition of claim
1 to form an article.
12. An article comprising the composition of claim 1, wherein the article is an extruded
or injection molded article, preferably a component of a hand-held electronic device
like a cellular telephone, or wherein the article is preferably in the form of a lens
for a cellular telephone.
13. The composition of claim 1 comprising, based on the total weight of the polymer components
in the composition,
3 to 15 wt.% of a polysiloxane polycarbonate block copolymer comprising repeating
structural units of formula (I)
wherein at least 60 percent of the total number of R1 groups are aromatic organic radicals and the balance thereof are aliphatic, alicyclic,
or aromatic radicals, and
repeating structural units of formula (IV)
wherein R2 is independently at each occurrence a monovalent organic radical having 1 to 13 carbon
atoms, R3 is a divalent aliphatic radical having 1 to 8 carbon atoms or an aromatic radical
having 6 to 8 carbon atoms, R4 is independently at each occurrence a hydrogen, halogen, alkoxy having 1 to 8 carbon
atoms, alkyl having 1 to 8 carbon atoms, or aryl having 6 to 13 carbon atoms, and
n is an integer less than or equal to 1000;
33 to 77 wt.% of a cycloaliphatic polyester having repeating units of formula (VI)
wherein R7 and R8 are independently at each occurrence a cycloaliphatic group-containing radical having
from 5 to 20 carbon atoms; and
17 to 65 wt.% of a polycarbonate that is different from the polycarbonate block copolymer,
having a weight average molecular weight of less than 20,000 Daltons, and that comprises
repeating structural units of formula (XVIII)
wherein at least 60 percent of the R9 groups are derived from a bisphenol of formula (XX)
wherein R10 and R11 independently at each occurrence are a halogen or a monovalent hydrocarbon group,
p and q are each independently integers from 0 to 4, and X represents one of the groups
of formula (XXI) or (XXII)
wherein R12 and R13 independently at each occurrence are a hydrogen or a monovalent linear or cyclic
hydrocarbon group having 1 to 8 carbon atoms and R14 is a divalent hydrocarbon group having 1 to 8 carbon atoms; and further wherein
the composition has a melt volume rate of 24 to 35 cm3/10 minutes, measured in accordance with ISO 1133 at 265°C and 2.16 kg, and
wherein a molded sample having a thickness of 3.2 mm has a Notched Izod impact strength
of 800 to 1600 J/m, measured in accordance with ASTM D-256 at 23°C.
14. The composition of claim 1 comprising, based on the total weight of the polymer components
in the composition,
4 to 7 wt.% of a polysiloxane polycarbonate block copolymer comprising
repeating structural units of formula (I)
wherein at least 60 wt.% of the R1 groups are derived from bisphenol A;
repeating structural units of formula (IV)
wherein R2 is independently at each occurrence a methyl, trifluoropropyl, or phenyl, R3 is propylene, and n is an integer of 10 to 100;
38 to 70 wt.% of poly(1,4-cyclohexane-dimethanol-1,4-dicarboxylate); and
25 to 55 wt.% of a polycarbonate that is different from the polycarbonate block copolymer,
having a weight average molecular weight of less than 19,000 Daltons, and that comprises
repeating structural units of formula (XVIII)
wherein at least 60 percent of the total number of R9 groups are derived from a bisphenol A; and further wherein
the composition has a melt volume rate of 24 to 35 cm3/10 minutes, measured in accordance with ISO 1133 at 265°C and 2.16 kg, and
wherein a molded sample having a thickness of 3.2 mm has a Notched Izod impact strength
of 800 to 1600 J/m, measured in accordance with ASTM D-256 at 23°C.
1. Zusammensetzung, umfassend, auf der Grundlage des Gesamtgewichts von Polymerkomponenten
in der Zusammensetzung,
3 bis 15 Gew.-% eines Polysiloxan-Polycarbonat-Blockcopolymers, umfassend strukturelle
Wiederholungseinheiten der folgenden Formel (I):
wobei mindestens 60 % der Gesamtanzahl von R1-Gruppen aromatische organische Reste sind und der Rest davon aliphatische, alicyclische
oder aromatische Reste sind, und
strukturelle Wiederholungseinheiten der folgenden Formel (IV)
wobei R2 unabhängig bei jedem Auftreten ein einwertiger organischer Rest mit 1 bis 13 Kohlenstoffatomen
ist, R3 ein zweiwertiger organischer Rest mit 1 bis 8 Kohlenstoffatomen oder ein aromatischer
Rest mit 6 bis 8 Kohlenstoffatomen ist, R4 unabhängig bei jedem Auftreten ein Wasserstoff, Halogen, Alkoxy mit 1 bis 8 Kohlenstoffatomen,
Alkyl mit 1 bis 8 Kohlenstoffatomen, oder Aryl mit 6 bis 13 Kohlenstoffatomen ist,
und n eine ganze Zahl von weniger als oder gleich 1000 ist;
33 bis 77 Gew.-% eines cycloaliphatischen Polyesters mit Wiederholungseinheiten der
Formel (VI)
wobei R7 und R8 unabhängig bei jedem Auftreten eine zweiwertige aromatische, aliphatische oder cycloaliphatische
Gruppe mit 2 bis 20 Kohlenstoffatomen sind, mit der Maßgabe, dass mindestens eines
von R7 und R8 ein eine cycloaliphatische Gruppe-enthaltender Rest ist; und
17 bis 65 Gew.-% eines Polycarbonats, das von dem Polycarbonat-Blockcopolymer verschieden
ist, mit einer gewichtsmittleren Molmasse von weniger als 20.000 Dalton, und welches
strukturelle Wiederholungseinheiten der Formel (XVIII) umfasst
wobei mindestens 60 % der Gesamtanzahl von R9-Gruppen aromatische organische Reste sind und der Rest davon aliphatische, alicyclische
oder aromatische Reste sind, und weiterhin
wobei die Zusammensetzung eine Schmelzvolumenrate von 20 bis 40 cm3/10 min aufweist, gemessen gemäß ISO 1133 bei 265 °C und 2,16 kg, und
wobei eine pressgeformte Probe mit einer Dicke von 3,2 mm eine Kerbschlagzähigkeit
von 800 bis 1600 J/m aufweist, gemessen gemäß ASTM D-256 bei 23 °C.
2. Zusammensetzung nach Anspruch 1, umfassend 4 bis 7 Gew.-% des Blockcopolymers, 38
bis 70 Gew.-% des cycloaliphatischen Polyesters, und 25 bis 55 Gew.-% des Polycarbonats.
3. Zusammensetzung nach Anspruch 1, wobei eine pressgeformte Probe mit einer Dicke von
3,2 mm eine Kerbschlagzähigkeit von 100 bis 1000 J/m aufweist, gemessen gemäß ASTM
D-256 bei 0 °C.
4. Zusammensetzung nach Anspruch 1, wobei die Zusammensetzung mindestens 10 % mehr Molekulargewicht
nach dem Altern für 28 Tage bei 80 °C, 80 % relativer Feuchtigkeit beibehält, im Vergleich
zu einer Zusammensetzung ohne das Polysiloxan-Polycarbonat-Blockcopolymer, und vorzugsweise
das Polycarbonat der Zusammensetzung mindestens 15 % mehr von seinem Molekulargewicht
nach dem Altern für 28 Tage bei 80 °C, 80 % relativer Feuchtigkeit beibehält, im Vergleich
zu einer Zusammensetzung ohne das Polysiloxan-Polycarbonat-Blockcopolymer, oder vorzugsweise
der Polyester der Zusammensetzung mindestens 10 % mehr von seinem Molekulargewicht
nach dem Altern für 28 Tage bei 80 °C, 80 % relativer Feuchtigkeit beibehält, im Vergleich
zu einer Zusammensetzung ohne das Polysiloxan-Polycarbonat-Blockcopolymer.
5. Zusammensetzung nach Anspruch 1, wobei ein geformter Gegenstand aus der Zusammensetzung
und mit einer Dicke von 2,5 mm eine Trübung von weniger als oder gleich 5 % aufweist,
gemessen gemäß ASTM D-1003-00, oder wobei eine pressgeformte Probe mit einer Dicke
von 3,2 mm eine Wärmeformbeständigkeit von 60 bis 90 °C aufweist.
6. Zusammensetzung nach Anspruch 1, wobei mindestens 60 Gew.-% der R1-Gruppen Reste der Formel (XIX) sind
-A3-Y2-A4- (XIX)
wobei A3 und A4 jeweils einen monocyclischen zweiwertigen Arylrest darstellen, und Y2 -O-, -S-, -S(O)2-, C(O)-, Methylen, Cyclohexylmethylen,
2-[2.2.1]-Bicycloheptyliden, Ethyliden, Isopropyliden, Neopentyliden, Cyclohexyliden,
Cyclopentadecyliden, Cycldodecyliden, Adamantyliden, oder eine mindestens eine der
vorgehenden Gruppen umfassende Kombination ist, und weiterhin wobei R2 unabhängig bei jedem Auftreten ein einwertiger organischer Rest mit 1 bis 4 Kohlenstoffatomen
ist, R3 ein zweiwertiger aliphatischer Rest mit 3 bis 8 Kohlenstoffatomen ist, und n eine
ganze Zahl von 10 bis 100 ist, A3 und A4 vorzugsweise jeweils Phenylen sind und Y2 Isopropyliden ist, und R2 Methyl ist, R3 ein zweiwertiger aliphatischer Rest mit 3 bis 8 Kohlenstoffatomen ist, und n eine
ganze Zahl von 40 bis 60 ist.
8. Zusammensetzung nach Anspruch 1, wobei sich R8 von 1,4-Cyclohexyldicarbozylsäure ableitet, wobei mehr als 70 Mol-% davon in der
Form des trans-Isomers vorliegen, und R7 sich von 1,4-Cyclohexyldimethanol ableitet, wobei mehr als 70 % davon in der Form
des trans-Isomers vorliegen.
9. Zusammensetzung nach Anspruch 1, wobei R
9 mindestens 60 Gew.-% von Einheiten der Formel (XX) umfasst
wobei R
10 und R
11 unabhängig bei jedem Auftreten ein Halogenatom oder eine einwertige Kohlenwasserstoffgruppe
sind; q und p jeweils unabhängig ganze Zahlen von 0 bis 4 sind; und X eine der Gruppen
der Formeln (XXI) oder (XXII) darstellt
wobei R
12 und R
13 unabhängig bei jedem Auftreten ein Wasserstoffatom oder eine einwertige lineare oder
cyclische Kohlenwasserstoffgruppe mit 1 bis 8 Kohlenstoffatomen sind und R
14 eine zweiwertige Kohlenwasserstoffgruppe mit 1 bis 8 Kohlenstoffatomen ist, vorzugsweise
X Isopropyliden ist und p und q jeweils Null sind.
10. Verfahren zur Herstellung der Zusammensetzung nach Anspruch 1, umfassend das Schmelzvermischen
der Komponenten der Zusammensetzung nach Anspruch 1.
11. Verfahren zum Herstellen eines Gegenstandes, umfassend Spritzguss, Extrusion, Injektionsguss,
gasunterstütztes Blasformen, oder Vakuumformen der Zusammensetzung nach Anspruch 1,
um einen Gegenstand herzustellen.
12. Gegenstand, umfassend die Zusammensetzung nach Anspruch 1, wobei der Gegenstand ein
extrudierter oder spritzgegossener Gegenstand, vorzugsweise eine Komponente von einer
elektronischen Handvorrichtung, wie ein Handy ist, oder wobei der Gegenstand vorzugsweise
in der Form von einer Linse für ein Handy vorliegt.
13. Zusammensetzung nach Anspruch 1, umfassend, bezogen auf das Gesamtgewicht der Polymerkomponenten
in der Zusammensetzung,
3 bis 15 Gew.-% eines Polysiloxan-Polycarbonat-Blockcopolymers, umfassend
strukturelle Wiederholungseinheiten der Formel (I)
wobei mindestens 60 Gew.-% der Gesamtanzahl der R1-Gruppen aromatische organische Rest sind und der Rest davon aliphatische, alicyclische
oder aromatische Reste sind, und
strukturelle Wiederholungseinheiten der Formel (IV)
wobei R2 unabhängig bei jedem Auftreten ein einwertiger organischer Rest mit 1 bis 13 Kohlenstoffatomen
ist, R3 ein zweiwertiger aliphatischer Rest mit 1 bis 8 Kohlenstoffatomen oder ein aromatischer
Rest mit 6 bis 8 Kohlenstoffatomen ist, R4 unabhängig bei jedem Auftreten ein Wasserstoff, Halogen, Alkoxy mit 1 bis 8 Kohlenstoffatomen,
Alkyl mit 1 bis 8 Kohlenstoffatomen, oder Aryl mit 6 bis 13 Kohlenstoffatomen ist,
und n eine ganze Zahl von weniger als oder gleich 1000 ist;
33 bis 77 Gew.-% eines cycloaliphatischen Polyesters mit Wiederholungseinheiten der
Formel (VI)
wobei R7 und R8 unabhängig bei jedem Auftreten ein eine cycloaliphatische Gruppe enthaltender Rest
mit 5 bis 20 Kohlenstoffatomen sind; und
17 bis 65 Gew.-% eines Polycarbonats, das von dem Polycarbonat-Blockcopolymer verschieden
ist, mit einer gewichtsmittleren Molmasse von weniger als 20.000 Dalton, und welches
strukturelle Wiederholungseinheiten der Formel (XVIII) umfasst
wobei sich mindestens 60 % der R9-Gruppen von einem Bisphenol der Formel (XX) ableiten
wobei R10 und R11 unabhängig bei jedem Auftreten ein Halogen oder eine einwertige Kohlenwasserstoffgruppe
sind, p und q jeweils unabhängig ganze Zahlen von 0 bis 4 sind, und X eine der Gruppen
der Formeln (XXI) oder (XXII) darstellen
wobei R12 und R13 unabhängig bei jedem Auftreten Wasserstoff oder eine einwertige lineare oder cyclische
Kohlenwasserstoffgruppe mit 1 bis 8 Kohlenstoffatomen sind und R14 eine zweiwertige Kohlenwasserstoffgruppe mit 1 bis 8 Kohlenstoffatomen ist; und weiterhin
wobei
die Zusammensetzung eine Schmelzvolumenrate von 24 bis 35m3/10 min aufweist, gemessen gemäß ISO 1133 bei 265 °C und 2,16 kg, und wobei eine pressgeformte
Probe mit einer Dicke von 3,2 mm eine Kerbschlagzähigkeit von 800 bis 1600 J/m aufweist,
gemessen gemäß ASTM D-256 bei 23 °C.
14. Zusammensetzung nach Anspruch 1, umfassend, bezogen auf das Gesamtgewicht der Polymerkomponenten
in der Zusammensetzung,
4 bis 7 Gew.-% eines Polysiloxan-Polycarbonat-Blockcopolymers, umfassend
strukturelle Wiederholungseinheiten der folgenden Formel (I):
wobei sich mindestens 60 % der R1-Gruppen von Bisphenol A ableiten;
strukturelle Wiederholungseinheiten der Formel (IV)
wobei R2 unabhängig bei jedem Auftreten ein Methyl, Trifluorpropyl oder Phenyl ist, R3 Propylen ist, und n eine ganze Zahl von 10 bis 100 ist;
38 bis 70 Gew.-% Poly(1,4-cyclohexan-dimethanol-1,4-dicarboxylat); und
25 bis 55 Gew.-% eines Polycarbonats, das von dem Polycarbonat-Blockcopolymer verschieden
ist, mit einer gewichtsmittleren Molmasse von weniger als 19.000 Dalton, und welches
strukturelle Wiederholungseinheiten der Formel (XVIII) umfasst
wobei sich mindestens 60 % der Gesamtanzahl der R9-Gruppen von einem Bisphenol A ableiten; und weiterhin
die Zusammensetzung eine Schmelzvolumenrate von 24 bis 35m3/10 min aufweist, gemessen gemäß ISO 1133 bei 265 °C und 2,16 kg, und
wobei eine pressgeformte Probe mit einer Dicke von 3,2 mm Kerbschlagzähigkeit von
800 bis 1600 J/m aufweist, gemessen gemäß ASTM D-256 bei 23 °C.
1. Composition comprenant, basé sur le poids total des composants polymères dans la composition,
3 à 15 % en poids d'un copolymère à bloc polysiloxane-polycarbonate comprenant des
unités structurelles récurrentes de la formule (I)
dans laquelle au moins 60% du nombre total de groupes R1 sont des radicaux organiques aromatiques et le reste de ceux-ci est aliphatique,
alicyclique, ou des radicaux aromatiques, et
des unités structurelles récurrentes de la formule (IV)
dans lesquelles R2 est, indépendamment en chaque occurrence, un radical organique monovalent ayant 1
à 13 atomes de carbone, R3 est un radical aliphatique divalent ayant 1 à 8 atomes de carbone ou un radical aromatique
ayant 6 à 8 atomes de carbone, R4 est, indépendamment en chaque occurrence, un hydrogène, halogène, alkoxy ayant 1
à 8 atomes de carbone, alkyle ayant 1 à 8 atomes de carbone ou aryle ayant 6 à 13
atomes de carbone, et n est un nombre entier inférieur ou égal à 1000 ;
33 à 77 % en poids d'un polyester cycloaliphatique ayant des unités structurelles
récurrentes de la formule (VI)
dans laquelle R7 et R8 sont, indépendamment en chaque occurrence, un groupe aromatique, aliphatique ou cycloaliphatique
divalent ayant 2 à 20 atomes de carbone, sous condition qu'au moins l'un parmi R7 et R8 soit un radical contenant un groupe cycloaliphatique ; et
17 à 65 % en poids d'un polycarbonate qui est différent du copolymère à bloc polycarbonate,
ayant une masse moléculaire moyenne en poids de moins de 20 000 daltons, et qui comprend
des unités structurelles récurrentes de la formule (XVIII)
dans laquelle au moins 60 % du nombre total de groupes R9 sont des radicaux organiques aromatiques et le reste de-ceux-ci est aliphatique,
alicyclique, ou des radicaux aromatiques, et en outre
dans laquelle la composition a une courbe de débit-volume de fonte de 20 à 40 cm3/10 minutes, mesurée conformément à ISO 1133 à 265°C et 2,16 kg, et
dans laquelle un échantillon moulé ayant une épaisseur de 3,2 mm possède une résistance
au choc Izod entaillé à 800 à 1600 J/m, mesurée conformément à ASTM D-256 à 23°C.
2. Composition selon la revendication 1, comprenant 4 à 7 % en poids d'un copolymère
à bloc, 38 à 70 % en poids d'un polyester cycloaliphatique, et 25 à 55% en poids du
polycarbonate.
3. Composition selon la revendication 1, dans laquelle un échantillon moulé ayant une
épaisseur de 3,2 mm possède une résistance au choc Izod entaillé à 100 à 1000 J/m,
mesurée conformément à ASTM D-256 à 0°C.
4. Composition selon la revendication 1, dans laquelle la composition conserve au moins
un 10% en plus de poids moléculaire après avoir vieilli pendant 28 jours à 80°C de
température, 80% d'humidité relative, par rapport à une composition sans le copolymère
à bloc de polysiloxane/polycarbonate, et en préférence le polycarbonate de la composition
conserve au moins 15% en plus de son poids moléculaire après avoir vieilli pendant
28 jours à 80°C de température, 80% d'humidité relative, par rapport à une composition
sans le copolymère à bloc de polysiloxane/polycarbonate, ou de préférence le polyester
de la composition conserve au moins 10% en plus de son poids moléculaire après avoir
vieilli pendant 28 jours à 80°C de température, 80% d'humidité relative, par rapport
à une composition sans le copolymère à bloc de polysiloxane/polycarbonate.
5. Composition selon la revendication 1, dans laquelle un article moulé à partir de la
composition et ayant une épaisseur de 2,5 mm a une opacité inférieure ou égale à 5%,
mesurée conformément à ASTM D-1003-00, ou a une transparence supérieure ou égale à
80%, mesurée conformément à ASTM D-1003-00, ou dans laquelle un échantillon moulé
ayant une épaisseur de 3,2 mm a une température de déformation de 60 à 90°C.
6. Composition selon la revendication 1, dans laquelle au moins un 60% en poids des groupes
R1 sont des radicaux avec la formule (XIX)
-A3-Y2-A4- (XIX)
dans laquelle chacun des A3 et A4 est un radical aryle divalent monocyclique et Y2 est -O-, -S-, -S(O)-,-S(O)2-, -C(O)-, méthylène, cyclohexyle méthylène,
2-[2.2.1]-bicycloheptylidène, éthylidène, isopropylidène, neopentylidène, cyclohexylidène,
cyclopentadecylidène, cyclododecylidène, adamantylidène, ou une combinaison comprenant
au moins l'un des groupes précédents, et en outre dans laquelle R2 est, indépendamment en chaque occurrence, un radical organique monovalent ayant 1
à 4 atomes de carbone, R3 est un radical aliphatique divalent ayant 3 à 8 atomes de carbone, et n est un nombre
entier compris entre 10 et 100, de préférence chacun parmi A3 et A4 est phénylène et Y2 est isopropylidène, et R2 est méthyle, R3 est un radical aliphatique divalent ayant 3 à 8 atomes de carbone, et n est un nombre
entier compris entre 40 et 60.
8. Composition selon la revendication 1, dans laquelle R8 est dérivé de l'acide cyclohexyle-1,4-dicarboxylique avec plus de 70 % en moles de
celle-ci en forme d'isomère trans et R7 est dérive de cyclohexyle-1,4-diméthanol avec plus de 70 % en moles de ceux-ci en
forme d'isomère trans.
9. Composition selon la revendication 1, dans laquelle R
9 inclut au moins un 60% en poids des unités de la formule (XX)
dans laquelle R
10 et R
11 sont, indépendamment en chaque occurrence, un atome d'halogène ou un groupe hydrocarburé
monovalent ; p et q chacun sont des nombres entiers indépendants l'un de l'autre de
0 à 4 ; et X représente l'un des groupes de la formule (XXI) ou (XXII)
dans laquelle R
12 et R
13 sont, indépendamment en chaque occurrence, un atome d'hydrogène ou un groupe hydrocarbure
linéaire monovalent ou cyclique ayant 1 à 8 atomes de carbone et R
14 est un groupe hydrocarbure divalent ayant 1 à 8 atomes de carbone; de préférence
X est isopropylidène et p et q sont chacun égaux à zéro.
10. Méthode de fabrication de la composition selon la revendication 1, comprenant l'étape
consistant à mélanger en coulée les composants de la composition selon la revendication
1.
11. Méthode pour le moulage d'un article, comprenant le moulage par injection, l'extrusion,
le moulage par injection-soufflage, le moulage par soufflage assisté par gaz, ou le
moulage sous vide de la composition selon la revendication 1 pour mouler un article.
12. Un article comprenant la composition selon la revendication 1, dans laquelle l'article
est un article moulé par extrusion ou par injection, de préférence un composant d'un
dispositif électronique portatif tel qu'un téléphone cellulaire, ou dans laquelle
l'article de préférence possède la forme d'une lentille pour le téléphone cellulaire.
13. Composition selon la revendication 1, comprenant, basée sur le poids total des composants
polymère dans la composition,
3 à 15 % en poids d'un copolymère à bloc de polysiloxane-polycarbonate comprenant
des unités structurelles récurrentes de la formule (I)
dans laquelle au moins un 60% du nombre total de groupes R1 sont des radicaux organiques aromatiques et le reste de ceux-ci est aliphatique,
alicyclique, ou des radicaux aromatiques, et
des unités structurelles récurrentes de la formule (IV)
dans lesquelles R2 est, indépendamment en chaque occurrence, un radical organique monovalent ayant 1
à 13 atomes de carbone, R3 est un radical aliphatique divalent ayant 1 à 8 atomes de carbone ou un radical aromatique
ayant 6 à 8 atomes de carbone, R4 est, indépendamment en chaque occurrence, un hydrogène, halogène, alkoxy ayant 1
à 8 atomes de carbone, alkyle ayant 1 à 8 atomes de carbone ou aryle ayant 6 à 13
atomes de carbone, et n est un nombre entier inférieur ou égal à 1000 ;
33 à 77 % en poids d'un polyester cycloaliphatique ayant des unités structurelles
récurrentes de la formule (VI)
dans laquelle R7 et R8 sont, indépendamment en chaque occurrence, un radical contenant un groupe cycloaliphatique
ayant de 5 à 20 atomes de carbone, et
17 à 65 % en poids d'un polycarbonate qui est différent du copolymère à bloc de polycarbonate,
ayant une masse moléculaire moyenne en poids inférieure à 20 000 Daltons, est qui
comprend des unités structurelles récurrentes de la formule (XVIII)
dans laquelle au moins un 60 % du nombre total de groupes R9 sont dérivés d'un bisphénol de la formule (XX)
dans laquelle R10 et R11 sont, indépendamment en chaque occurrence, halogène ou un groupe hydrocarburé monovalent
; p et q chacun sont des nombres entiers indépendants l'un de l'autre allant de 0
à 4 ; et X représente l'un des groupes de la formule (XXI) ou (XXII)
dans laquelle R12 et R13 sont, indépendamment en chaque occurrence, hydrogène ou un groupe hydrocarbure monovalent
linéaire ou cyclique ayant 1 à 8 atomes de carbone et R14 est un groupe hydrocarbure divalent ayant 1 à 8 atomes de carbone ; et en outre dans
laquelle
la composition a une courbe de débit-volume de fonte de 24 à 35 cm3/10 minutes, mesurée conformément à ISO 1133 à 265°C et 2,16 kg, et
dans laquelle un échantillon moulé avec une épaisseur de 3,2 mm possède une résistance
au choc Izod entaillé à 800 à 1600 J/m, mesurée conformément à ASTM D-256 à 23°C.
14. Composition selon la revendication 1 comprenant, basée sur le poids total des composants
polymères dans la composition,
4 à 7 % en poids d'un copolymère à bloc polysiloxane/polycarbonate, comprenant des
unités structurelles récurrentes de la formule (I)
dans laquelle au moins 60% en poids des groupes R1 sont dérivés du bisphénol A ;
des unités structurelles récurrentes de la formule (IV)
dans laquelle R2 est, indépendamment en chaque occurrence, un méthyle, trifluoropropyle, ou phényle,
R3 est propylène, et n est un nombre entier compris entre 10 et 100 ;
38 à 70 % en poids de poly(1,4-cyclohexane-diméthanol-1,4-dicarboxylate) ; et
25 à 55% en poids d'un polycarbonate qui est différent du copolymère à bloc de polycarbonate,
ayant une masse moléculaire moyenne en poids inférieure à 19 000 Daltons, et qui comprend
des unités structurelles récurrentes de la formule (XVIII)
dans laquelle au moins 60 % du nombre total de groupes R9 sont dérivés du bisphénol A ; et en outre dans laquelle
la composition a une courbe de débit-volume de fonte de 24 à 35 cm3/10 minutes, mesurée conformément à ISO 1133 à 265°C et 2,16 kg, et
dans laquelle un échantillon moulé ayant une épaisseur de 3,2 mm, une résistance au
choc Izod entaillé à 800 à 1600 J/m, mesurée conformément à ASTM D-256 à 23°C.